Custom Six-Panel Hats: Embroidery, Patches and Free Mockups

Quick answerA six-panel hat is built from six triangular panels that meet at a button on top, with two panels forming the front. It is the most common baseball cap and trucker shape. Logos are centered across the front seam, which embroidery and patches handle easily on a structured crown.
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What is a six-panel hat?

Most trucker hats, snapbacks, fitted caps and dad hats are six-panel caps. The center front seam is backed by buckram on structured styles, so it barely shows under a decoration.

Six-panel caps also have two side panels and two back panels, which gives you clean side and back locations for extra logos.

Best decorations for six-panel hats

  • Embroidery and 3D puff. Stitching crosses the seam with no trouble and is the classic six-panel look.
  • Patches of every type. A structured six-panel front holds patches flat across the seam.
  • Side and back logos. Use the side panels for a small icon and the back for a website or slogan.

Logo size guide

LocationTypical maximum
Front crownup to 5″ wide, about 2.25″ tall
Left or right sideup to about 1.9″ wide
Back, above the closureup to about 3.4″ wide

Every hat differs slightly. The visualizer shows your logo's exact size in inches as you resize it, and Decorators United confirms sizing on your proof.

How to mock up a six-panel hat

  1. Open the Hat Visualizer. It is free and runs in your browser. No account needed.
  2. Choose your hat and color. Pick a hat style, or upload photos of your own hat.
  3. Upload your logo. PNG, JPG, SVG or WebP. It appears on the hat at real size in inches.
  4. Pick a decoration. Compare embroidery, 3D puff, leatherette, leather, woven, PVC and more.
  5. Download or request a quote. Save the mockup, or send it to Decorators United for pricing and a proof.

Six-panel hats: common questions

Does the center seam affect embroidery?

Not on a structured hat. The seam is flattened and backed, so embroidery and patches sit smoothly across it.

Are trucker hats six-panel?

Most are. A standard trucker hat has two foam or twill front panels and four mesh panels at the sides and back.

Where can I put logos on a six-panel hat?

The front crown, the left and right sides, and the back above the closure. The visualizer lets you design each view and export them together.

Related hat guides

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